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Resistance welding is a group of welding processes in whichcoalescence is produced by the heat obtained from resistance of thework piece to electric current in a circuit of which the work piece is apart and by the application of pressure. There are at least sevenimportant resistance-welding processes.

Resistance welding is a group of welding processes in which coalescence isproduced by the heat obtained from resistance of the work piece to electriccurrent in a circuit of which the work piece is a part and by the application ofpressure. There are at least seven important resistance-welding processes.These are flash welding, high-frequency resistance welding, percussionwelding, projection welding, resistance seam welding, resistance spotwelding, and upset welding. They are alike in many respects but aresufficiently different.

Resistance spot welding (RSW) is a resistance welding process whichproduces coalescence at the faying surfaces in one spot by the heat obtainedfrom resistance to electric current through the work parts held togetherunder pressure by electrodes.

The size and shape of the individually formed welds are limited primarily bythe size and contour of the electrodes. The equipment for resistance spotwelding can be relatively simple and inexpensive up through extremely largemultiple spot welding machines. The stationary single spot welding machinesare of two general types: the horn or rocker arm type and the press type.

The horn type machines have a pivoted or rocking upper electrode arm,which is actuated by pneumatic power or by the operator`s physical power.They can be used for a wide range of work but are restricted to 50 kVA andare used for thinner gauges. For larger machines normally over 50 kVA, thepress type machine is used. In these machines, the upper electrode moves ina slide. The pressure and motion are provided on the upper electrode byhydraulic or pneumatic pressure, or are motor operated.

For high-volume production work, such as in the automotive industry,multiple spot welding machines are used. These are in the form of a press onwhich individual guns carrying electrode tips are mounted. Welds are madein a sequential order so that all electrodes are not carrying current at thesame time.

Projection welding (RPW) is a resistance welding process which producescoalescence of metals with the heat obtained from resistance to electricalcurrent through the work parts held together under pressure by electrodes.

The resulting welds are localized at predetermined points by projections,embossments, or intersections. Localization of heating is obtained by aprojection or embossment on one or both of the parts being welded. Thereare several types of projections: (1) the button or dome type, usually round,(2) elongated projections, (3) ring projections, (4) shoulder projections, (5)cross wire welding, and (6) radius projection.

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The Welding Processes:Resistance Welding

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The major advantage of projection welding is that electrode life is increasedbecause larger contact surfaces are used. A very common use of projectionwelding is the use of special nuts that have projections on the portion of thepart to be welded to the assembly.

Resistance seam welding (RSEW) is a resistance welding process whichproduces coalescence at the faying surfaces the heat obtained fromresistance to electric current through the work parts held together underpressure by electrodes.

The resulting weld is a series of overlapping resistance spot welds madeprogressively along a joint rotating the electrodes. When the spots are notoverlapped enough to produce gaslight welds it is a variation known as rollresistance spot welding. This process differs from spot welding since theelectrodes are wheels. Both the upper and lower electrode wheels arepowered. Pressure is applied in the same manner as a press type welder. Thewheels can be either in line with the throat of the machine or transverse. Ifthey are in line it is normally called a longitudinal seam welding machine.Welding current is transferred through the bearing of the roller electrodewheels. Water cooling is not provided internally and therefore the weld areais flooded with cooling water to keep the electrode wheels cool.

In seam welding a rather complex control system is required. This involvesthe travel speed as well as the sequence of current flow to provide foroverlapping welds. The welding speed, the spots per inch, and the timingschedule are dependent on each other. Welding schedules provide thepressure, the current, the speed, and the size of the electrode wheels.

This process is quite common for making flange welds, for making watertightjoints for tanks, etc. Another variation is the so-called mash seam weldingwhere the lap is fairly narrow and the electrode wheel is at least twice as wideas used for standard seam welding. The pressure is increased toapproximately 300 times normal pressure. The final weld mash seamthickness is only 25% greater than the original single sheet.

Flash Welding (FW) is a resistance welding process which producescoalescence simultaneously over the entire area of abutting surfaces, by theheat obtained from resistance to electric current between the two surfaces,and by the application of pressure after heating is substantially completed.

Flashing and upsetting are accompanied by expulsion of metal from the joint.During the welding operation there is an intense flashing arc and heating ofthe metal on the surface abutting each other. After a predetermined time thetwo pieces are forced together and coalescence occurs at the interface,current flow is possible because of the light contact between the two partsbeing flash welded.

The heat is generated by the flashing and is localized in the area between thetwo parts. The surfaces are brought to the melting point and expelledthrough the abutting area. As soon as this material is flashed away anothersmall arc is formed which continues until the entire abutting surfaces are atthe melting temperature. Pressure is then applied and the arcs areextinguished and upsetting occurs.

Upset welding (UW) is a resistance welding process which producescoalescence simultaneously over the entire area of abutting surfaces orprogressively along a joint, by the heat obtained from resistance to electriccurrent through the area where those surfaces are in contact.

Pressure is applied before heating is started and is maintained throughoutthe heating period. The equipment used for upset welding is very similar tothat used for flash welding. It can be used only if the parts to be welded areequal in cross-sectional area. The abutting surfaces must be very carefullyprepared to provide for proper heating.

The difference from flash welding is that the parts are clamped in the weldingmachine and force is applied bringing them tightly together. High-amperagecurrent is then passed through the joint, which heats the abutting surfaces.When they have been heated to a suitable forging temperature an upsettingforce is applied and the current is stopped. The high temperature of the workat the abutting surfaces plus the high pressure causes coalescence to takeplace. After cooling, the force is released and the weld is completed.

Percussion welding (PEW) is a resistance welding process which producescoalescence of the abutting members using heat from an arc produced by arapid discharge of electrical energy.

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Pressure is applied progressively during or immediately following theelectrical discharge. This process is quite similar to flash welding and upsetwelding, but is limited to parts of the same geometry and cross section. It ismore complex than the other two processes in that heat is obtained from anarc produced at the abutting surfaces by the very rapid discharge of storedelectrical energy across a rapidly decreasing air gap. This is immediatelyfollowed by application of pressure to provide an impact bringing the twoparts together in a progressive percussive manner. The advantage of theprocess is that there is an extremely shallow depth of heating and time cycleis very short. It is used only for parts with fairly small cross-sectional areas.

High frequency resistance welding (HFRW) is a resistance welding processwhich produces coalescence of metals with the heat generated from theresistance of the work pieces to a high-frequency alternating current in the10,000 to 500,000 hertz range and the rapid application of an upsetting forceafter heating is substantially completed. The path of the current in the workpiece is controlled by the proximity effect.

This process is ideally suited for making pipe, tubing, and structural shapes. Itis used for other manufactured items made from continuous strips ofmaterial. In this process the high frequency welding current is introducedinto the metal at the surfaces to be welded but prior to their contact witheach other.

Current is introduced by means of sliding contacts at the edge of the joint.The high-frequency welding current flows along one edge of the seam to thewelding point between the pressure rolls and back along the opposite edgeto the other sliding contact.

The current is of such high frequency that it flows along the metal surface toa depth of several thousandths of an inch. Each edge of the joint is theconductor of the current and the heating is concentrated on the surface ofthese edges. At the area between the closing rolls the material is at theplastic temperature, and with the pressure applied, coalescence occurs.

Date Published: Apr-2002